Fabrication System For Continuously Fabricating Graded Extended Length Lumber With Maximum Grade Utilization Of Input Low Quality Raw Lumber

ABSTRACT

An extended length graded lumber fabrication system features a number of fabrication stages along a substantially continuous fabrication path providing high through put fabrication of graded lumber of extended length from low quality raw lumber. The fabrication stages include reject recognition stages, a supply lumber grading stage, a finger jointing stage and a final grading stage for the extended length lumber. The fabrication system is configured in conjunction with the particularities of low quality raw lumber to minimize grade fluctuations, increase grade bandwidth and minimize raw lumber waste during fabrication of extended length graded lumber, which may be used in wooden truss joists. The use of low quality raw lumber cut from small diameter tree trunks is environmentally beneficial. It contributes to preserve old growth and to use lighter and environmentally less invasive timber harvesting machinery and techniques.

FIELD OF INVENTION

The present invention relates to fabrication systems and plants forfabricating extended length lumber. In particular, the present inventionrelates to fabrication systems and plants for continuously fabricatingextended length graded lumber of low quality raw lumber.

BACKGROUND OF INVENTION

In the field of architectural construction, lumber is an importantstructural material needed in variable grades and lengths for trusses,wall frames and the like. Well known fingerjointing techniques areemployed in the lumber industry to provide lumber at lengthsindependently of the length of the available raw lumber. Fingerjointingis also used to provide lumber substantially without lumber strengthdegrading elements such as wood eyes, wanes and bents. The grading ofthe lumber on the other hand is accomplished by well known machinerythrough which the lumber may be continuously feed. The minimal length ofindividual finger jointed pieces is determined by method and fabricationsystem by means of which extended length lumber may be economicallyfeasible mass produced. At the time of this invention, the minimallength of individual finger jointed pieces and consequently the spacingbetween finger joints of common extended length lumber is down to about1 foot. As may be well appreciated by anyone skilled in the art withreducing lumber piece length a larger percentage of the raw lumber maybe utilized. Lumber utilization becomes increasingly important asstrength degrading lumber elements increase. Therefore, there exists aneed for a fabrication system that provides for economically feasiblefabrication of extended length lumber with spacing between finger jointsof less than 1 foot. The present invention addresses this need.

For environmental benefit it is desirable to utilize low quality rawlumber that may be cut from small diameter tree trunks, which maycontribute to preserve old growth and may promote lighter andenvironmentally less invasive timber harvesting machinery andtechniques. Unfortunately, low quality raw lumber has a relatively largepercentage of wanes, wood rind, wood eyes, bents and other strengthdegrading elements that degrade the technical and economic feasibilityof low quality raw lumber particularly for fabricating graded structurallumber in common fabrication systems and plants. Nevertheless, lowquality raw lumber such as for example well known US No. 2 type utilitylumber has a theoretical content of at least 75% of well known 1650grade and higher. Therefore, there exists a need for a fabricationsystem and method for continuously fabricating graded extended lengthlumber with maximum grade utilization of input low quality raw lumber.The present invention addresses also this need.

SUMMARY

An extended length graded lumber fabrication system features a number offabrication stages along a substantially continuous input-to-outputfabrication path providing high through put fabrication of graded lumberof extended length in conjunction with the particularities of lowquality raw lumber. The fabrication stages include reject recognitionstages, a supply lumber grading stage, a lumber sorting stage withadditional graded lumber buffer storage paths diverting off thecontinuous input-to-output fabrication path, a lumber length extensionstage and an extended length grading stage.

The reject recognition stages may include a lumber appearance inspectionand out-sorting stage, a moisture measuring stage and a graininconsistency scanning stage. At a reject cutout and grade separationstage lumber strength degrading elements rejected in the previousscanning stage are cut out. Lumber segments with different grade ratingsare also separated. The reject cutout and grade separation stage iscomputerized controlled in accordance with grade, grain inconsistencyinformation obtained at their respective stages. Grade sorted nominaland shortened length lumber propagates along secondary and tertiarygraded lumber buffer storage paths onto a storage paths switching stageat which buffer storage requirements of the continuously processedsupply lumber are dynamically adjusted for a continuous buffer storingand grade selective in-feeding into the continuous input-to outfabrication path immediately prior to the lumber length extension stage.

At the lumber length extension stage well known finger jointingmachinery joints the individual graded and reject cleared lumber piecesinto a substantially endless single grade lumber string. Part of thelumber length extension stage may also be a well known finger jointproof loader and a travel saw. The finger joint proof loader tests thefinger joints according to well known specific finger joint testcriteria, which differ from lumber grading criteria. The travel saw cutscomputerized controlled the endless lumber coming from the fingerjointer into the final extended length and cuts out failed finger jointsas well as grade transitions after a dynamic grade fabrication change inthe fabrication system. Due to the lumber grading prior to the lumberlength extension stage, grade fluctuations of the endless lumber stringare brought to a minimum. In the second lumber grading stage the gradeof the extended length lumber is verified in accordance with existinggrading requirements at the end of the extended lumber fabrication.

Well known chord(s) and/or well known web strut(s) of a well knownwooden truss joist may be made of the single grade extended lengthlumber fabricated by fabrication system of the present invention.

The fabrication system may also feature a reject back insertion pathdiverting off the continuous input-to-output fabrication path followingthe travel saw and terminating at begin of the continuousinput-to-output fabrication path where the raw lumber is in-feed. Theraw lumber, the failed finger joint lumber and grade transition lumbermay define together with eventual other scrap lumber like from trussfabrication the supply lumber.

Two separate well known lumber testing machines are preferably employedat the respective first and second lumber grading stage. Nevertheless,the scope of the invention includes an embodiment in which a singlelumber grading machine is employed such that the first and second lumbergrading stages coincide. Consequently, the continuous input-to-outputfabrication path crosses at the coinciding first and second lumbergrading stages.

Dual lumber grading is highly advantageous in minimizing gradefluctuations in the final extended length lumber. Secondary and tertiarygraded lumber buffer storage paths in combination with the automatedlumber sorting and buffer storage path switching provide for economicmass production of single grade extended length with finger jointspacing of less than 1 foot down to about 4 inches. The tertiary lumberbuffer storage path and the reject back insertion path assist also inincreasing fabrication economy by reducing lumber waste. The secondaryand tertiary lumber buffer storage paths are parallel to the continuousinput-to-output fabrication path with computer controlled switchinggates that provide together with buffer storage along the individualpaths for real time grade switching during extended length lumberfabrication. In summary, minimized grade fluctuations in the finalextended length lumber, extended lumber grade bandwidth, reduced lumberwaste and real time grade switching contribute to a maximum utilizationof input low quality raw lumber. In addition, dynamic grade transitionsare accomplished without interrupting the fabrication flow. This is animportant aspect in particular in combination with utilized low qualityraw lumber and mass fabricated truss components with grade variationstailored to the well known diverse needs in architectural constructions,

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 a is a schematic prior art figure of standard quality raw lumbersamples.

FIG. 1 b shows a schematic prior art figure of low quality raw lumbersamples as preferably utilized in the present invention.

FIG. 2 depicts a block diagram of a representative first embodiment ofthe invention.

FIG. 3 is a block diagram of a representative second embodiment of theinvention.

FIG. 4 shows a schematic floor plan of a fabrication system according tothe block diagram of FIG. 3.

FIG. 5 depicts a schematic wooden truss joist.

DETAILED DESCRIPTION

For the purpose of general understanding of the present invention incombination with the particularities of low quality raw lumber, priorart FIGS. 1 a and 1 b schematically depict a representative assortmentof standard quality lumber SQ and low quality lumber LQ. The standardquality lumber SQ of FIG. 1 a may be in minimum grade x along sectionsLGX. Standard quality lumber SQ has limited number of wood eyes WE andother well known lumber strength degrading elements and/or defects.Certain standards for lumber straightness may also apply to the standardquality lumber SQ

Low quality lumber LQ depicted in prior art FIG. 1 b may be of a lengthbetween 1-20 feet, with an increased number of lumber strength degradingelements and/or defects such as, wood eyes WE, rinds RD, wanes WN andother well known grain inconsistencies. Standards for straightness maybe also lower than in standard quality lumber SQ. The resulting minimumutilizable grade length LG1-LG4 in a low quality lumber LQ may be downto 4 inches. In case of well known United States No. 2 utility lumber,about 75% of the low quality LQ boards with their grade lengths LG1-LG4of well known 1650 grade and higher.

For an economically and technically feasible fabrication of single gradeextended length lumber from low quality lumber LQ, certain fabricationsteps, stages and paths are introduced in the present invention toaccount for the particularities of low quality raw lumber LQ. Suchparticularities may include the minimum utilizable grade length LG1-LG2of down to 4 inches, as well as larger grade fluctuations.

As shown in FIG. 2, a first embodiment of the invention includes themethod steps 10 of providing generic lumber, followed by the step 13 ofinspecting lumber pieces for defects and/or insufficiencies. The sidestep 131 of removing rejected pieces takes place in conjunction withstep 13. Step 13 may include but is not limited to well known visualinspection, well known moisture scanning, and/or well known wood eyescanning. The next step 16 includes initial lumber piece grading intogrades A-N and the associated step 162 of associating grade informationwith the graded lumber pieces. Step 16 and 162 may be performed by awell known lumber grading machine such as the METRIGUARD™ Model 7200lumber tester. In the consecutive step 22, the lumber pieces are gradesorted in association with the grade information of step 162. Inconjunction with step 22, grades B-N lumber pieces are buffer stacked inside step 221. Following both step 22 and step 221 is step 28 in whichgrade selective in-feeding of grade A-N lumber pieces is performedfollowed by step 30 of finger jointing the in-fed grade selected lumberpieces into a single grade A-N endless lumber. The endless lumber isthen proof loaded in step 32 and in the associated step 322, a fingerjoint failure information is associated with the corresponding endlesslumber location. After step 32, the single grade A-N endless lumber islengthened into extended length single grade lumber and failed fingerjoints are removed in step 34. In a final grading step 36, the extendedlength lumber pieces are graded.

Steps 10, 13, 16, 22, 28, 30, 32, 34, 36 take place along asubstantially continuous input-to-output fabrication path CP along whichthe lumber is substantially continuously propagating as single piecesand/or in stacks. The step 221 takes place along a secondary gradedlumber buffer storage path SP. The secondary graded lumber bufferstorage path SP diverts off the continuous input-to-output path CPfollowing step 22 and rejoins the continuous input-to-output fabricationpath CP at beginning of step 28.

In FIG. 3, a second preferred embodiment of the invention includes themethod steps 10 of providing generic raw lumber, followed by the step 12of in-feeding supply lumber pieces including the raw lumber and returnin-fed lumber from steps 144 and 342. After scanning lumber moisture instep 18, lumber appearance is inspected in step 14 and excess moistureboards are removed in step 142 The side step 141 of removing rejectedpieces that did not pass the appearance inspection takes also place inconjunction with step 14. Appearance inspection is preferably performedby trained personnel. The removed moist lumber may be dried as in step143 and return in-fed as in step 144. The repeated appearance inspectionof dried lumber warrants that well known excess lumber bending or wellknown lumber cracking that may occur during drying are recognized andremoved. Moisture scanning of step 18 may be accomplished by a wellknown WAGNER™ Apex Moisture Detector.

The next step 16 includes initial grading of the supply lumber piecesinto grades A-N and the associated step 162 of associating gradeinformation with the graded lumber pieces. Steps 16 and 162 may beperformed by a well known lumber grading machine such as the METRIGUARD™Model 7200 lumber tester. The lumber pieces propagate along thecontinuous input-to-output fabrication path CP from the initial lumbergrading towards the following step 20, in which the lumber pieces arescanned for grain inconsistencies such as wood eyes WE. The graininconsistency information is associated with the lumber pieces inassociated step 202. Steps 20 and 202 may be performed by a well knownNEWNESS™ Advantage Scanner.

In the consecutive step 22, the nominal length lumber pieces graininconsistency testing are grade sorted in association with the gradeinformation of step 162. In conjunction with step 22, grades B-N nominallength lumber pieces are secondary buffer stacked in side step 221.Nominal length in context with the present invention means the length ofthe raw lumber without scrap lumber and finger joint failure lumber. Thenominal length in a preferred embodiment of the invention is between2-20 feet. Following both step 22 and step 221 is step 24 in which graininconsistencies and excess moisture portions M are removed from thelumber pieces. In conjunction with step 241, grades A-N cut lumberpieces are tertiary buffer stacked in side step 241.

Next is step 28 in which grade selective in-feeding of grade A-N lumberpieces is performed followed by step 30 of finger jointing the in-fedgrade selected lumber pieces into a single grade A-N endless lumberstring. The endless lumber string is then proof loaded in step 32 and inthe associated step 322, a finger joint failure information isassociated with the corresponding endless lumber location. After step32, the single grade A-N endless lumber string is lengthened intoextended length single grade lumber in step 34. Lumber portionsincluding the failed finger joints and/or grade transitions are removedin the corresponding side step 341. The cut out lumber portions are keptat a predetermined length for return in-feeding them at step 12 asindicated by step 342. In a final grading step 36, the extended lengthlumber pieces are graded.

Steps 10, 12, 14, 16, 18, 20, 22, 24, 28, 30, 32, 34, 36, 38 take placealong a substantially continuous input-to-output fabrication path CPalong which the lumber is substantially continuously propagating assingle pieces and/or in stacks. The step 221 takes place along asecondary graded lumber buffer storage path SP. The secondary gradedlumber buffer storage path SP diverts off the continuous input-to-outputpath CP following step 22 and rejoins the continuous input-to-outputfabrication path CP at beginning of step 28. The step 241 takes placealong a tertiary graded shortened lumber buffer storage path TP. Thetertiary graded shortened lumber buffer storage path TP diverts off thecontinuous input-to-output path CP following step 24 and rejoins thecontinuous input-to-output fabrication path CP at beginning of step 28.Steps 341 and 342 take place along a reject back insertion path RPdiverting off the continuous input-to-output fabrication path CPfollowing step 34 and terminating at beginning of step 12.

The schematic floor plan of a preferred embodiment of the fabricationsystem 200 is shown in FIG. 4. Along the substantially continuousinput-to-output fabrication path CP propagate lumber pieces ofpredetermined cross section such as 2 by 4 inches on well known conveyorand/or other transport systems commonly utilized for piecewise and/orstack wise continuous lumber transport. At the begin of the continuousinput-to-output fabrication path CP is a multiple lengths supply lumberin-feed stage including a hydraulic break down hoist 2122 and smallpiece conveyor 2124. The hydraulic break down hoist 2122 breaks downstacked nominal length lumber that is in-fed via a first fork liftaccess 2101 and an in-feed deck 2121. Short length lumber pieces, whichmay be down to 1 foot length are in-fed into the continuousinput-to-output fabrication path CP via a second fork lift access 2102connecting to the small piece conveyor 2124.

After the moisture scanner 218, a lumber appearance inspection andout-sorting stage may include an inspection deck 214 and a thirdforklift access 2141. On the inspection deck, the spread lumber piecesgradually move along in lateral direction at a speed suitable for apreferred visual inspection and manual reject removal by trainedpersonnel. The rejected boards are stacked at the third forklift access2141 for removal.

Following the inspection deck 214 is a lateral chain feeder 2161 thatredirects the remaining boards into longitudinal propagation directiontowards the lumber tester 2162 of a first lumber grading stage, themoisture detector 218 of a moisture measuring stage, and the scanner 220of a grain inconsistency scanning stage. Then the lumber enters anautomated lumber sorter 222 in which the lumber pieces are laid out forfurther processing and/or out-sorting as part of a nominal length lumbergrade sorting stage. From the sorter 222, a nominal length conveyor 2222receives nominal length boards grade B-N that have passed the graininconsistency scanning. The sorter 222 may utilize grade informationfrom the first lumber grader 2162 and grain inconsistency informationobtained from the scanner 220 to perform the out-sorting in acomputerized controlled fashion. Ink marks imprinted on the lumber inthe lumber grader 2162 and/or the scanner 220 may be recognized by wellknown machine vision systems, which may include a camera. Grade markingmay be for example via bar code or color code. Additionally, lengthinformation may also be coded onto the shortened length boards. Incontext with the present invention grade A may be preferably a grademost common for the particular quality raw in-fed lumber. In arepresentative case of No. 2 utility raw lumber, grade A may be the wellknown 1650 grade. Hence, the highest capacity throughput directly alongthe continuous input-to-output fabrication path CP is utilized in themost economic fashion. The nominal length conveyor 2222 terminates at astorage path switching stage in the preferred configuration of a pulltable 225 and a turn table 2252. At the pull table 225 the nominallength boards are manually sorted at secondary pull cart accesses 2225in single grade stacks. The secondary graded lumber buffer storage pathSP, which begins at the secondary pull cart accesses 2225 and terminatesat the pull-cart in-feed 2287 may include well known temporary bufferstorage locations not shown on the schematic plan.

Behind the automated lumber sorter 222 is a reject cutout and gradeseparation saw 224, from which a short piece conveyor 2242 diverts. Awaste bin 2243 that automatically captures the out cut rejected lumberportions is placed along the short piece conveyor 2242. Also part of thestorage path switching stage are tertiary cart accesses 2245, turn table2252 and tertiary first fork lift accesses 2246. Lumber pieces havingportions that failed the grain inconsistency scanning and/or have morethan one grade LG1-LG4 along their length are computerized controlleddiverted towards the saw 224 where the rejected lumber portions are cutout in accordance with the grain inconsistency information and gradelengths LG1-LG4 are separated in accordance with grade information fromthe supply lumber grader 2162. The remaining grade A-N shortened lengthlumber pieces end up on the pull table 225 together with the grade B-Nsorted nominal length boards. Employing a storage path switching stagefor grade selective sorting of nominal and shortened length boardsprovides necessary flexibility to adjust to varying grade compositionsof the supplied and/or raw lumber. On the pull table 225 boards in thelength down to about 2 feet are sorted. On the adjacent turn table 2252,boards of lengths down to about 6 inches are manually grade sortedstacked on pallets on the tertiary first fork lift accesses 2246 forfurther fork lift manipulation. The tertiary graded lumber bufferstorage paths TP, which begin at the tertiary accesses 2245, 2246 andterminate at the in-feeds 2287 and 2280 may include well known temporarybuffer storage locations not shown on the schematic plan. The manuallyoperated pull table 225 and turn table 2252 may be substituted by anautomatic tables and/or well known robotic equipment as may be wellappreciated by anyone skilled in the art

The remaining grade A nominal length lumber passes through a stackerin-feed 2261, a stacker 2262 and stack jump roll case 2263, where it iseither directly redirected via a stack cross over rollcase 2281 towardsa single grade lumber length extension stage or buffer stored in betweenan stack out-feed deck 2264 and stack in-feed deck 2283. Stack out-feeddeck 2264 has a forth fork lift access 2265 and the stack in-feed deck2283 has a fifth fork lift access 2282.

Buffer storing of the nominal length grade A lumber may be at a wellknown buffer storage location (not shown) along the continuousinput-to-output fabrication path CP. It may be utilized while grade B-Nlumber is in-fed at the grade selective in-feeding stage, which furtherincludes a stack jump rollcase 2284 for alternately receiving nominallength grade A lumber from stack crossover rollcase 2281 or from stackin-feed deck 2283. Pull cart stacked boards may be manually in-fed fromstack in-feed 2287 onto a singulation station at which the lumber may beheld back temporarily while single grade shortened pieces are in-fed viasixth fork lift access 2280, pallet dumper 2289 and spreader conveyor2288.

The lumber sorter 222, stack jump rollcases 2263, 2284, stack cross overroll case, singulation station 2286 and short piece conveyor 2288 withpallet dumper 2289 are computer controlled switching gates that providetogether with buffer storage along the individual paths CP, SP, TP inbetween the switching gates for real time grade switching withsubstantially uninterrupted extended length lumber fabrication.

The grade selective in-fed lumber pieces are transported towards alumber length extension stage including a well known profile machinewhere the ends of the lumber pieces are machined for finger jointing.The lumber length extension stage further includes well known componentssuch as an assembler conveyor 2304, crowder 2305, curing station 2306,retarder 2307, a proof loader 232 and a travel saw 234. An incline chaindeck 2302 and a corner feeder 2303 transport the lumber between theprofile machine 2301 and the assembler conveyor 2304.

The endless lumber string propagating out of the curing station 2306passes through the proof loader 232, where finger joint testing isperformed in accordance with well known finger joint test criteria.Finger joint failure information is passed onto the travel saw 234 for acomputerized controlled out-cutting of failed finger joints inaccordance with the finger joint failure information. Failed fingerjoint portions as well as grade transitions are kept at a minimum lengthof preferably about 1 foot for out-sorting at sweep table 2344 andreinsertion via seventh fork lift access 2345 and second fork liftaccess 2102 via reject back insertion path RP. The travel saw 234 alsocuts the endless lumber string into extended length lumber of preferably66 feet length, which is diverted by the sweep table 2344 towards asecond lumber grader 236 and a paddle stacker 2381. There, the extendedlength lumber is stacked and transported away via eight fork lift access2382. The second lumber grader may be similar to the first lumber grader2162.

In a further embodiment of the invention, a single lumber graded isutilized instead of two lumber graders 2162 and 236. Consequently, thecontinuous input-to-output fabrication path CP crosses at the first rawlumber grading stage coinciding with the second extended length lumbergrading stage.

In FIG. 5, a wooden truss joist 300 has top chords 301, bottom chords302 and web struts 303. Chords 301, 302 and/or struts 303 may befabricated from extended length graded lumber fabricated as abovedescribed and/or in accordance with the above described fabricationsystem 200.

Accordingly, the scope of the invention described in the specificationand figures is set forth by the following claims and their legalequivalent:

1. An extended length graded lumber fabrication system comprising: a. acontinuous input-to-output fabrication path; b. a lumber rejectrecognition stage along said continuous input-to-output fabricationpath; c. a supply lumber grading stage along said continuousinput-to-output fabrication path; d. a grade sorting stage along saidcontinuous input-to-output fabrication path behind said lumber rejectrecognition stage and said first supply lumber grading stage; e. asingle grade lumber length extension stage along said continuousinput-to-output fabrication path and following said grade sorting stage;and f. an extended length lumber grading stage along said continuousinput-to-output fabrication path and behind said single grade lengthextension stage.
 2. The extended length graded lumber fabrication systemof claim 1, further comprising a secondary graded lumber buffer storagepath diverting off said continuous input-to-output path behind saidgrade sorting stage and rejoining said continuous input-to-outputfabrication path before said single grade lumber length extension stage.3. The extended length graded lumber fabrication system of claim 1,wherein said reject recognition stage is behind said first lumbergrading stage along said continuous input-to-output fabrication path,and wherein said extended length graded lumber fabrication systemfurther comprises: a. a reject cutout and grade separation stagefollowing said reject recognition stage along said continuousinput-to-output fabrication path; b. a tertiary graded shortened lumberbuffer storage path diverting off said continuous input-to-outputfabrication path behind said reject cutout stage and rejoining saidcontinuous input-to-output fabrication path before said single gradelumber length extension stage.
 4. The extended length graded lumberfabrication system of claim 1, wherein at least a portion of saidextended length graded lumber is a chord of a truss joist.
 5. Theextended length graded lumber fabrication system of claim 1, wherein atleast a portion of said extended length graded lumber is a web strut ofa truss joist.
 6. The extended length graded lumber fabrication systemof claim 1, wherein said extended length graded lumber has a spacingbetween finger joints of less than 1 foot and down to about 4 inches. 7.The extended length graded lumber fabrication system of claim 1, whereina first lumber grader is provided at said supply lumber grading stageand wherein a second lumber grader is provided at said extended lengthlumber grading stage.
 8. The extended length graded lumber fabricationsystem of claim 1, wherein a single lumber graded is at said supplylumber grading stage coinciding with said extended length lumber gradingstage and wherein said continuous input-to-output fabrication pathcrosses at said supply lumber grading stage coinciding with saidextended length lumber grading stage.
 9. An extended length gradedlumber fabrication system comprising: a. a continuous input-to-outputfabrication path; b. a lumber reject recognition stage along saidcontinuous input-to-output fabrication path; c. a supply lumber gradingstage along said continuous input-to-output fabrication path; d. anautomated lumber sorting stage along said continuous input-to-outputfabrication path following said lumber reject recognition stage and saidfirst raw lumber grading stage; e. a secondary graded lumber bufferstorage path diverting off said continuous input-to-output fabricationpath at said automated lumber grading stage; f. a reject cutout andgrade separation saw following said automated lumber sorting stage; g. atertiary graded shortened lumber buffer storage path diverting off saidcontinuous input-to-output fabrication path at said reject cut out andgrade separation saw; h. a storage path switching stage along saidsecondary graded lumber buffer storage path and said tertiary bufferstorage path; i. a single grade lumber length extension stage along saidcontinuous input-to-output fabrication path and following said gradesorting stage; and j. an extended length lumber grading stage along saidcontinuous input-to-output fabrication path and following said singlegrade length extension stage; wherein said secondary graded lumberbuffer storage path and said tertiary graded shortened lumber bufferstorage path rejoin said continuous input-to-output fabrication pathbefore said single grade lumber length extension stage.
 10. The extendedlength graded lumber fabrication system of claim 9, wherein at least aportion of said extended length graded lumber is a chord of a trussjoist.
 11. The extended length graded lumber fabrication system of claim9, wherein at least a portion of said extended length graded lumber is aweb strut of a truss joist.
 12. The extended length graded lumberfabrication system of claim 9, wherein said extended length gradedlumber has a spacing between finger joints of less than 1 foot and downto about 4 inches.
 13. The extended length graded lumber fabricationsystem of claim 9, wherein a first lumber grader is provided at saidsupply lumber grading stage and wherein a second lumber grader isprovided at said extended length lumber grading stage.
 14. The extendedlength graded lumber fabrication system of claim 9, wherein a singlelumber graded is at said supply lumber grading stage coinciding withsaid extended length lumber grading stage and wherein said continuousinput-to-output fabrication path crosses at said supply lumber gradingstage coinciding with said extended length lumber grading stage.
 15. Afabrication system for continuously fabricating multiple grade extendedlength lumber from low quality variable length supply lumber, saidfabrication system comprising: a. a continuous input-to-outputfabrication path along which lumber pieces of predetermined crosssection propagate; b. a multiple lengths supply lumber in-feed stage atbegin of said continuous input-to-output fabrication path, said multiplelengths supply lumber in-feed stage being configured for receiving andin-feeding supply lumber in form of said lumber pieces in an originallength and shorter; c. a moisture measuring stage following saidmultiple lengths supply lumber in-feed stage along said continuousinput-to-output fabrication path, wherein at said moisture measuringstage a moisture information is associated with said lumber pieces; d. alumber appearance inspection and out-sorting stage following saidmultiple lengths supply lumber in-feed along said continuousinput-to-output fabrication path; e. a supply lumber grading stagefollowing said lumber appearance inspection and out-sorting stage alongsaid continuous input-to-output fabrication path, wherein at said lumbergrading stage a grade information is associated with said lumber pieces;f. a grain inconsistencies scanning stage following said lumberappearance inspection and out-sorting stage along said continuousinput-to-output fabrication path, wherein at said grain inconsistenciesscanning stage a grain inconsistency information is associated with saidlumber pieces; g. a grade sorting stage following said graininconsistency scanning stage along said continuous input-to-outputfabrication path, wherein at said grade sorting stage said lumber piecesare computerized controlled diverted onto a secondary graded nominallength lumber buffer storage path in accordance with at least one ofsaid grade information and said grain inconsistency information; h. areject cutout and grade separation stage following said grade sortingstage along said continuous input-to-output fabrication path, wherein atsaid reject cutout grade separation stage said lumber pieces arecomputerized controlled diverted towards a cutout saw and onto atertiary shortened length graded lumber buffer storage path inaccordance with said grade information and said grain inconsistencyinformation, and wherein said cutout saw is computerized controlled inaccordance with said grain inconsistency information such that portionsof said lumber pieces having a grain failure are removed; i. a gradeselective in-feeding stage at which said secondary graded originallength lumber buffer storage path and said tertiary graded lumbershortened length buffer storage path are rejoining said continuousinput-to-output path, and wherein at said grade selective in-feedingstage at least one of said graded original length lumber and saidshortened length graded lumber of a predetermined single grade arein-fed into said continuous input-to-output path; j. a single gradelumber length extension stage following said grade selective in-feedingstage along said continuous input-to-output fabrication path, whereinsaid single grade lumber extension stage features: i. a finger jointerjoining said at least one of said graded original length lumber and saidshortened length graded lumber into a propagating endless lumber; ii. afinger joint proof loader at which a finger joint failure information isassociated with an endless lumber location; iii. a travel sawcomputerized controlled cutting said endless lumber into said extendedlength lumber and out-cutting failed finger joints in accordance withsaid finger joint failure information; and k. an extended length lumbergrading stage along said continuous input-to-output fabrication path andfollowing said single grade length extension stage.
 16. The fabricationsystem of claim 15, further comprising a reject back insertion pathdiverting off said continuous input-to-output fabrication path behindsaid travel saw, wherein said reject back insertion path terminates atsaid multiple lengths supply lumber in-feed stage such that cutoutlumber having a failed finger joint is reinserted at begin of saidcontinuous input-to-output path.
 17. The fabrication system of claim 15,wherein at least a portion of said extended length graded lumber is aweb strut of a truss joist.
 18. The fabrication system of claim 15,wherein at least a portion of said extended length graded lumber is achord of a truss joist.
 19. The extended length graded lumberfabrication system of claim 15, wherein said extended length gradedlumber has a spacing between finger joints of less than 1 foot and downto about 4 inches.
 20. A method for maximizing graded lumber output fromlow quality input lumber, said method comprising the steps of: a.providing generic lumber pieces; b. inspecting lumber pieces for atleast one of defects, excess moisture and insufficiencies and removingrejected lumber pieces; c. initial lumber piece grading into grades A-Nand associating a grade information with said lumber pieces; d. lumberpiece grade sorting in association with said grade information andbuffer stacking grades B-N lumber pieces; e. grade selective in-feedingof grade A-N lumber pieces; f. finger jointing into single grade A-Nendless lumber; g. proof loading endless lumber and associating fingerjoint failure information with endless lumber location; h. lengtheningsingle grade A-N endless lumber into extended length and removing failedfinger joints in association with said finger joint failure information;and i. final lumber piece grading.
 21. A method for maximizing gradedlumber output from low quality input lumber, said method comprising thesteps of: a. providing generic lumber pieces; b. in-feeding genericlumber pieces; c. scanning moisture of generic lumber pieces; d.inspecting appearance of lumber pieces and removing rejected and excessmoisture lumber pieces; e. drying excess moisture lumber pieces andreinserting said dried lumber pieces at step b; f. initial lumber piecegrading into grades A-N and associating initial grade information withlumber pieces; g. grain inconsistencies scanning and associating graininconsistency information with lumber pieces; h. nominal length lumbergrade sorting in association with said initial grade information, saidmoisture information and said grain inconsistency information andsecondary buffer stacking grade B-N nominal length lumber; i. graininconsistencies and excess moisture removing in association with saidmoisture information and said grain inconsistency information andtertiary buffer stacking grade A-N cut lumber in A-N grade and a-nlength Aa-Nn stacks; j. grade selective in-feeding of grade A-N lumberpieces; k. finger jointing into single grade A-N endless lumber; l.proof loading endless lumber and associating finger joint failureinformation with endless lumber location; m. lengthening single gradeA-N endless lumber into extended length, removing failed finger jointsin association with said finger joint failure information and returnin-feeding failed joint lumber at said step of in-feeding generic lumberpieces; and n. final lumber piece grading.